Optimizing parameters of warp fatigue life tester by response surface methodology

Abstract

The aim of this article was to provide an effective measurement method of the warp dynamic load capacity based on a warp fatigue life tester for sized yarns. Five parameters which affected the fatigue life of warp, respectively, namely, load frequency, warp speed, pre-tension weight, heald frame stroke, and static tension of the warp fatigue life tester, were studied. First, the influences of the five parameters on warp fatigue life were analyzed through single-factor experiments, and then, the Box–Behnken design based on the response surface methodology was adopted to optimize warp fatigue life tester parameters. The results showed that the optimum parameter conditions of the warp fatigue life tester for warp fatigue life were as follows: when heald frame stroke at 77.16 mm, load frequency of 205.49 times/min, and static tension as 6.96 cN, the optimal warp fatigue life was 1394.05 times. The theoretical and experimental values were in reasonable agreement, and the relative error was less than 1%. Verification and repeated trial results showed that the optimal parameters had good reproducibility, and the warp fatigue life tester with the optimal parameters provided an effective and reliable evaluation to the warp frictional, stretching, and buckling effects.